CN112080625A - High-speed rail axle surface induction quenching process with speed per hour being more than or equal to 400 kilometers, high-speed rail axle and production method thereof - Google Patents
High-speed rail axle surface induction quenching process with speed per hour being more than or equal to 400 kilometers, high-speed rail axle and production method thereof Download PDFInfo
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
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Abstract
The invention provides a high-speed railway axle surface induction quenching process with the speed per hour being more than or equal to 400 kilometers, a high-speed railway axle and a production method thereof, and the high-speed railway axle comprises the following components: 0.26 to 0.29 percent of C, 0.25 to 0.35 percent of Si, 0.62 to 0.82 percent of Mn, 0.010 percent of trace of P, 0.010 percent of trace of S, 0.95 to 1.18 percent of Cr0, 0.22 to 0.28 percent of Mo0, 0.60 to 1.40 percent of Ni0.020 to 0.060 percent of V, 0.015 to 0.040 percent of Al, less than or equal to 0.20 percent of Cu, and the balance of Fe and other inevitable impurities. After the axle is subjected to normalizing, quenching and high-temperature tempering heat treatment, surface induction quenching and low-temperature tempering are carried out on the whole length, the surface hardness of the axle is more than or equal to 650HV, the surface residual compressive stress exceeds-800 MPa, the fatigue strength exceeds 860MPa, and the operating requirement of high-speed rail with the speed per hour of more than or equal to 400 kilometers is met.
Description
Technical Field
The invention belongs to the technical field of high-speed rail axles, and particularly relates to a steel surface induction quenching process for a high-speed rail axle with a long fatigue life and a speed per hour of more than or equal to 400 kilometers.
Background
The axle is an ultra-large step-shaped axisymmetric part, the maximum diameter of the axle exceeds 200mm, the length of the axle can reach 2320mm, the axle and wheels are connected in an interference manner to form a wheel pair, and the axle bears the whole weight of a rolling stock, so that the axle is one of three key parts of a railway rolling stock. The heavy loading and high speed are the key development directions of high-speed trains, axles are the heaviest key moving parts of single bodies, and the improvement of fatigue performance is the constant theme of axle steel research and development.
Due to different national conditions and different technical viewpoints of various countries, the axle materials selected are different. From the practice of foreign high-speed railway transportation, the application of carbon steel and low-carbon alloy steel axles is feasible, but has various advantages and disadvantages.
Chinese patent CN101857914A published in 10/13/2010 discloses a heat treatment method of a 25CrMo alloy steel hollow axle material for a high-speed railway passenger car, and the axle performance can meet the requirements of a train with the speed of 200-. However, the materials and the process adopted by the patent can not meet the requirement of the train with the speed per hour being more than 350 kilometers.
Chinese patent CN101649387A published in 2/17/2010 discloses a heat treatment method for an axle, which adopts a mixed liquid quenching and tempering process to enable a 42CrMo axle to meet the requirements of a railway locomotive axle. This patent is applicable to the train that the speed of a motor vehicle is lower, and the tensile strength of axletree can not satisfy high-speed train's needs.
Chinese patent CN107988563A published in 2018, 5, month and 4 discloses a fine-grain ultrahigh-toughness axle steel and a heat treatment method thereof, which indicates that the tensile strength of the axle can be kept about 1000MPa and the grain size is about 11 μm by the process of quenching and tempering twice. The patent adopts twice quenching to increase energy consumption, has no economy, and although the obdurability of the material is improved, the material lacks fatigue performance and can not be directly applied to high-speed railway axles with the speed of 400 kilometers per hour. The domestic research on the heat treatment process of the axle steel is only a conventional heat treatment process and lacks a novel heat treatment process.
The European high-speed rail axle adopts alloy steel integral tempering to ensure the axle fatigue performance, while the Japanese high-speed rail axle adopts a carbon steel surface induction quenching treatment mode to ensure the axle fatigue performance. The surface induction quenching is carried out on the Japan new mainline S38C, the depth of a hardening layer is 4mm, the surface hardness is more than or equal to 500HV, the fatigue strength is improved by more than 30 percent, and the highest speed per hour can reach 320 kilometers at present. Carbon steel has low obdurability, larger axle body size, alloy steel has better obdurability matching, and the axle size is relatively smaller, but if the fatigue performance is further improved, the axle size needs to be increased or the alloy content needs to be increased. Increasing the alloy content increases the material cost and is not economical.
With the rapid development of rail transit industry, particularly coastal high-speed rail construction, higher requirements are put forward on the performance of high-speed rail axles, although the research on the high-speed rail axles in China has a certain accumulation, the current requirements of trains with the speed per hour being less than or equal to 350 kilometers are only met, the research on the heat treatment process of the high-speed rail axles with the high fatigue life and the speed per hour being more than or equal to 400 kilometers is almost blank, and the development of the heat treatment process of the high-speed rail axles with the speed per hour being more than or equal to 400 kilometers and higher fatigue strength is urgently needed.
Disclosure of Invention
The invention aims to provide a high-speed railway axle surface induction quenching process with the speed per hour being more than or equal to 400 kilometers.A design optimized induction quenching process has the axle surface hardness being more than or equal to 650HV, the surface residual compressive stress exceeding-800 MPa and the fatigue strength exceeding 860MPa, and the fatigue strength (428MPa) of an axle sample is improved by more than 101% compared with that of the axle sample without surface induction quenching.
The invention also aims to provide a production method of the high-speed rail axle, which is characterized in that after the axle is subjected to heat treatment of normalizing, quenching and high-temperature tempering, the axle is treated by using the induction quenching process, so that the axle can be used for high-speed rail running at the speed per hour of more than or equal to 400 kilometers.
The invention finally aims to provide a high-speed rail axle which is produced by designing optimized components and utilizing the production method.
The specific technical scheme of the invention is as follows:
a high-speed railway axle surface induction quenching process with the speed per hour being more than or equal to 400 kilometers comprises the following steps:
1) when the surface induction quenching is carried out, the quenching machine tool is vertical, and the axle is vertically arranged; bending deformation caused by self weight in the axle quenching process is reduced to the maximum extent;
2) the heating inductor and the water spraying coil move axially at a constant speed along the longitudinal direction of the axle;
3) when the surface is quenched by induction, the quenching machine tool needs to drive the axle to rotate;
4) the water spraying coil is provided with a plurality of rows of different angles;
5) quenching and water spraying are carried out from bottom to top;
6) the current frequency of the induction hardening equipment is selected according to the following formula: 15000/H2<f<250000/H2Where f is the current frequency, unit: hz, H is the depth of the hardening layer, unit: mm.
The step 1) is specifically as follows: carrying out full-length surface induction quenching on high-speed rail axle steel with the maximum diameter of 226mm and the length of 2320mm, wherein a quenching machine tool is vertical, and an axle is vertically placed to reduce deformation in the axle quenching process;
in the step 2), the heating inductor and the water spray coil axially move at a constant speed along the longitudinal direction of the axle, the moving speed can be continuously adjusted according to the requirement of the depth of a hardening layer, and the quenching moving speed of the wheel seat part is 100-; the heating inductor and the water spraying coil can be finely adjusted along the horizontal direction so as to ensure that the axle is positioned in the middle of the coil.
Further, in the step 2), because the axle is in a stepped structure, the diameter difference between the wheel seat and the axle body is large, the heating temperature of the heating sensor is difficult to be ensured to be uniform in the continuous heating process, in order to heat all parts of the axle uniformly as far as possible, the moving speed of the heating sensor needs to be controlled in a segmented manner, the axle body part, the transition part and the wheel seat part adopt different quenching moving speeds, the axle body part and the transition part with small diameters are far away from the heating sensor, the heating temperature is low, the quenching moving speed needs to be correspondingly reduced so as to ensure the heating effect, according to the diameter difference between the wheel seat and the axle body and the actual quenching condition, the quenching moving speed of the axle body part is reduced to 80-180mm/min, and the quenching moving speed of the transition part is reduced to 90-210 mm/min;
in the step 3), the quenching machine tool drives the axle to rotate at 0-60r/min so as to ensure that the axle is uniformly heated and cooled.
And 4), the included angle between the nozzle and the lower end of the axle in the step 4) ranges from 90 degrees to 150 degrees, and the included angle can be properly adjusted according to different axle types so as to ensure that the R-angle transition part of the axle is well and uniformly cooled. Preferably, the water spray coils are arranged in 3-5 rows.
In the step 5), quenching and water spraying are carried out from bottom to top, and proper water pressure and water spraying time are ensured; the water pressure is 0.20-0.30MPa, the water spraying time is proper to ensure full cooling, and the temperature is less than 100 ℃ after cooling;
in step 6), the current skin depth and the current frequency are in inverse proportion in the induction heating process, so that the current frequency needs to be selected to be matched with the requirement of the depth of the hardening layer. The current frequency of the induction hardening equipment is selected according to the following formula: 15000/H2<f<250000/H2Wherein f is the current frequency (unit: Hz), and H is the depth of the hardening layer(unit: mm).
In addition, the selection of the current frequency has a certain relation with the diameter of the part, the axle is a large-size part, the middle-lower limit frequency is preferably selected when the current frequency is selected, the current frequency is selected to be 1000-3000Hz, and the depth of a hardening layer is 4-10 mm. Because the hardening layer depth of the axle needs to be determined by an axle-breaking tester, the target hardening layer depth of the axle in the actual production process needs to be determined by a large number of testers, and in order to reduce the test times and the test cost, the hardening layer depth H (unit: mm) of the axle can be estimated by the following formula: h ═ kPTt/v, where k is a constant related to the steel grade, the quenching frequency, the part diameter and the heat treatment state, and ranges from 4 × 10-4-6×10-4(unit: mm)2V (kW. DEG. C. s. min)), the specific value is adjusted accordingly according to the actual test result, and T is the heating temperature (unit: c), t is heating time (unit: s), P is heating power (unit: kW), v is the quenching speed (in mm/min) of the wheel seat portion of the axle.
A production method of a high-speed railway axle is produced by adopting the surface induction quenching process of the high-speed railway axle with the speed per hour of more than or equal to 400 kilometers, and comprises the following process flows: axle blank forging → rough turning of blank axle → processing of axle flush end face → heat treatment → fine turning processing of axle excircle → boring processing of axle inner hole → excircle grinding → fault detection → surface induction quenching → low temperature tempering → excircle grinding.
Because the axle belongs to an ultra-large step-shaped axisymmetric part and has larger size, the fatigue property of the axle is ensured by adopting a mode of integrally tempering alloy steel with better obdurability matching and higher hardenability for both the European high-speed railway axle and the domestic high-speed railway axle at present, but the alloy steel high-speed railway axle at home and abroad is only suitable for high-speed rails with the speed per hour being less than or equal to 350km at present. The alloy steel has stronger hardenability, can obtain a more uniform tempered sorbite structure after integral normalizing, quenching and high-temperature tempering heat treatment, easily obtain austenite with uniform components in the induction quenching heating process, and is converted into a uniform martensite structure after surface induction quenching, so that a high-hardness hardening layer is formed on the surface layer of the axle, the fatigue property of the axle is greatly improved, and the alloy steel is suitable for high-speed rails with the speed per hour being more than or equal to 400 kilometers.
The heat treatment includes normalizing, quenching and high temperature tempering.
And (3) normalizing: heating to 890-920 ℃, preserving the heat for 4-6h, and then cooling to below 400 ℃;
and (3) quenching: heating the normalized high-speed rail axle to 880-910 ℃, preserving heat for 4-6h, and then cooling to below 100 ℃ by water; the water temperature is 15-30 ℃;
tempering: heating the quenched high-speed rail axle to 600-660 ℃, preserving heat for 6-8h, and then air-cooling to below 100 ℃;
after the surface induction quenching, heating to 150-250 ℃, preserving the heat for 2-4h, and then cooling to below 80 ℃ in air (low-temperature tempering) to eliminate the internal stress.
And (5) finely grinding the surface of the axle after tempering is finished.
The high-speed rail axle provided by the invention is produced by adopting the production method, and comprises the following chemical components in percentage by mass: 0.26 to 0.29 percent of C, 0.25 to 0.35 percent of Si, 0.62 to 0.82 percent of Mn, 0.010 percent of trace of P, 0.010 percent of trace of S, 0.95 to 1.18 percent of Cr, 0.22 to 0.28 percent of Mo, 0.60 to 1.40 percent of Ni, 0.020 to 0.060 percent of V, 0.015 to 0.040 percent of Al, less than or equal to 0.20 percent of Cu, and the balance of Fe and other inevitable impurities.
Compared with the prior art, the axle is pretreated by normalizing, quenching and high-temperature tempering to obtain a uniform tempered sorbite structure, austenite with uniform components is easily obtained in the induction quenching and heating process, and the austenite is transformed into a uniform martensite structure after surface induction quenching, so that a high-hardness hardened layer (the surface hardness is more than or equal to 650HV) is formed on the surface layer of the axle, the hardness and the strength of the surface layer are greatly improved, the surface plastic distortion resistance of a sample is improved, meanwhile, residual compressive stress is formed on the surface of the axle, the near-surface residual compressive stress exceeds-800 MPa, the effective tensile stress born by the surface layer of the sample is greatly reduced, and the endurance limit stress of the surface layer is obviously improved; in addition, when induction quenching is heated, the phase transition temperature is high, the austenite nucleation rate is high, and sufficient time is not available for growth, so that the actual grain size of the austenite of the quenched layer is far smaller than the grain size of a matrix part, the grain size of a surface layer is obviously refined, the grain size of a matrix structure is 8.0-8.5 grade, and the grain size of the surface layer after surface strengthening is 12.0 grade; the fatigue property (the fatigue strength is more than or equal to 860MPa) is improved, and the fatigue property is improved by over 102 percent compared with the fatigue strength (426MPa) of an axle sample without surface induction quenching.
Drawings
FIG. 1 is a surface microstructure (500X) of the axle produced in example 1;
FIG. 2 is a surface microstructure (500X) of the axle produced in comparative example 1.
Detailed Description
The following examples are intended to illustrate the invention, but the scope of protection of the invention is not limited to the following examples.
Example 1
A production method of a high-speed rail axle adopts a surface induction quenching process to produce, and comprises the following process flows: axle blank forging → rough turning of blank axle → processing of axle flush end face → heat treatment → fine turning processing of axle excircle → boring processing of axle inner hole → excircle grinding → fault detection → surface induction quenching → low temperature tempering → excircle grinding.
The high-speed rail axle in example 1 comprises the following chemical components in percentage by weight: see table 1. The balance not shown in table 1 is Fe and inevitable impurities.
TABLE 1 EXAMPLES AND COMPARATIVE EXAMPLES chemical composition (unit: wt%)
During production, the heat treatment includes normalizing, quenching and high-temperature tempering.
And (3) normalizing: heating to 890-920 ℃, preserving the heat for 4-6h, and then cooling to below 400 ℃;
and (3) quenching: heating the normalized high-speed rail axle to 880-910 ℃, preserving heat for 4-6h, and then cooling by water (the water temperature is 15-30 ℃) to be below 100 ℃;
tempering: heating the quenched high-speed rail axle to 600-660 ℃, preserving heat for 6-8h, and then air-cooling to below 100 ℃;
example 1 specific heat treatment process parameters are given in table 2 below.
TABLE 2 Heat treatment Process for examples and comparative examples
Example 1 the results of mechanical property test of the axle steel after heat treatment are shown in Table 3.
TABLE 3 mechanical Properties of the examples and comparative examples
The axle subjected to the heat treatment is subjected to axle outer circle finish turning → axle inner hole boring → outer circle grinding → flaw detection → surface induction quenching → low-temperature tempering → outer circle grinding. The surface induction hardening specifically comprises the following steps:
1) carrying out full-length surface induction quenching on high-speed rail axle steel with the maximum diameter of 226mm and the length of 2320mm, wherein a quenching machine tool is vertical, and an axle is vertically placed to reduce deformation in the axle quenching process;
2) the heating inductor and the water spraying ring are finely adjusted along the horizontal direction to ensure that the axle is positioned in the middle of the coil; the heating inductor and the water spraying ring move axially at a constant speed along the longitudinal direction of the axle, the quenching moving speed of the wheel seat part is 100-240mm/min, the diameter difference between the wheel seat and the axle body is large because the axle is of a stepped structure, the heating inductor is difficult to ensure uniform heating temperature in the continuous heating process, in order to heat all parts of the axle uniformly as far as possible, the moving speed of the heating inductor needs to be controlled in sections, the axle body part, the transition part and the wheel seat part adopt different quenching moving speeds, the axle body part and the transition part with small diameters need to slow down correspondingly because of being far away from the heating inductor, the heating temperature is low, and the quenching moving speed needs to be slowed down correspondingly to ensure the heating effect, according to the diameter difference between the wheel seat and the shaft body and the actual quenching condition, the quenching moving speed of the shaft body is slowed down to 80-180mm/min, and the quenching moving speed of the transition position is slowed down to 90-210 mm/min;
3) when the surface is quenched by induction, the quenching machine tool drives the axle to rotate at 0-60r/min so as to ensure that the axle is uniformly heated and cooled;
4) the water spraying coils are arranged in four rows of different angles (the included angle between the nozzle and the lower end of the axle ranges from 90 degrees to 150 degrees), so that the R-angle transition part of the axle is well and uniformly cooled;
5) quenching and water spraying are carried out from bottom to top, the water pressure is 0.20-0.30MPa, the water spraying time is proper to ensure full cooling, and the temperature after cooling is less than 100 ℃;
6) the current frequency of the induction quenching equipment needs to be selected according to the following formula: 15000/H2<f<250000/H2Wherein f is the current frequency (unit: Hz), and H is the depth of the hardening layer (unit: mm). In addition, the selection of the current frequency has a certain relation with the diameter of the part, the axle is a large-size part, the middle and lower limit frequency is preferably selected when the current frequency is selected, the current frequency is selected to be 1000-3000Hz, and the depth of the hardening layer is 4-10 mm.
7) After the surface induction quenching, heating to 150-.
The specific process parameters of induction hardening of the surface of example 1 are shown in Table 4.
Table 4 example and comparative example surface induction quenching process
Examples 2 to 3 and comparative example 1 used the same composition and production method as in example 1, except that examples 2 to 3 differ from example 1 in the surface induction quenching process, and example 4 used the same quenching process parameters as in example 1, except that example 4 differs from example 1 in the composition and heat treatment process; comparative example 1 no laser quenching was used and comparative example 2 used the same quenching process parameters as in example 1, except that the comparative example 2 was different in composition and heat treatment process from example 1. The laser quenching processes of the examples and comparative examples are shown in table 4.
The fatigue strength (test standard: GB/T4337), the surface hardness (test standard: GB/T4340) and the maximum compressive stress (test standard: GB/T7704) of examples 1 to 4 (case hardening) are compared with those of comparative example 1 (case hardening was not performed), comparative example 2 (after laser hardening) in Table 5, the microstructure of the axle surface of examples (case hardening) and comparative example (case hardening was not performed) is shown in FIGS. 1 to 2, and the grain size before and after hardening is shown in Table 6.
TABLE 5 comparison of fatigue strength, surface hardness and surface maximum compressive residual stress for examples and comparative examples
TABLE 6 grain size of examples and comparative examples
As can be seen, the cycle number of fatigue cycles of each example after the induction hardening was 1X 108The fatigue strength is more than or equal to 860MPa, the surface hardness is more than or equal to 650HV, the surface residual compressive stress exceeds-800 MPa, the fatigue strength of the axle sample without surface induction quenching (426MPa) in the examples 1-4 is respectively improved by 102%, 106%, 109% and 103%, and compared with the comparative example 2 adopting the same surface induction quenching process, the fatigue strength is improved by 353 MPa.
Claims (10)
1. The surface induction quenching process of the high-speed rail car axle with the speed per hour being more than or equal to 400 kilometers is characterized by comprising the following steps of:
1) when the surface induction quenching is carried out, the quenching machine tool is vertical, and the axle is vertically arranged;
2) the heating inductor and the water spraying coil move axially at a constant speed along the longitudinal direction of the axle;
3) when the surface is quenched by induction, the quenching machine tool drives the axle to rotate;
4) the water spraying coil is provided with a plurality of rows of different angles;
5) quenching and water spraying are carried out from bottom to top;
6) the current frequency of the induction hardening equipment is selected according to the following formula: 15000/H2<f<250000/H2Where f is the current frequency, unit: hz, H is the depth of the hardening layer, unit: mm.
2. The surface induction quenching process for the high-speed railway axle with the speed per hour of more than or equal to 400 kilometers as recited in claim 1, wherein in the step 2), the heating inductor and the water spray ring axially move at a constant speed along the longitudinal direction of the axle, the quenching moving speed of the wheel seat part is 100-240mm/min, the quenching moving speed of the axle body part is slowed down to 80-180mm/min, and the quenching moving speed of the transition part is slowed down to 90-210 mm/min.
3. The surface induction quenching process of the high-speed railway axle with the speed per hour being more than or equal to 400 kilometers as recited in claim 1, wherein in the step 3), the quenching machine drives the axle to rotate at 0-60 r/min.
4. The high-speed railway axle surface induction quenching process with the speed per hour being more than or equal to 400 kilometers as recited in claim 1, wherein the included angle between the nozzle and the lower end of the axle in the step 4) ranges from 90 degrees to 150 degrees.
5. The surface induction quenching process of the high-speed railway axle with the speed per hour being more than or equal to 400 kilometers as recited in claim 1, wherein in the step 5), quenching and water spraying are carried out from bottom to top, the water pressure is 0.20-0.30MPa, and the temperature after water spraying and cooling is less than 100 ℃.
6. The surface induction quenching process of a high-speed railway axle with the speed per hour of more than or equal to 400 kilometers as claimed in claim 1, wherein the current frequency in the step 6) is selected from 1000-3000Hz, and the depth of the hardening layer is 4-10 mm.
7. A production method of a high-speed railway axle is characterized in that the production method is carried out by adopting the surface induction quenching process of the high-speed railway axle with the speed per hour being more than or equal to 400 kilometers as defined in any one of claims 1 to 6, and comprises the following process flows: axle blank forging → rough turning of blank axle → processing of axle flush end face → heat treatment → fine turning processing of axle excircle → boring processing of axle inner hole → excircle grinding → fault detection → surface induction quenching → low temperature tempering → excircle grinding;
the heat treatment includes normalizing, quenching and high temperature tempering.
8. The production method according to claim 7, wherein the normalizing: heating to 890-920 ℃, preserving the heat for 4-6h, and then cooling to below 400 ℃;
and (3) quenching: heating the normalized high-speed rail axle to 880-910 ℃, preserving heat for 4-6h, and then cooling to below 100 ℃ by water;
tempering: heating the quenched high-speed rail axle to 600-660 ℃, preserving heat for 6-8h, and then air-cooling to below 100 ℃.
9. The production method as claimed in claim 7, wherein the low temperature tempering is heating to 150 ℃ and 250 ℃ for 2-4h, and then air cooling to below 80 ℃.
10. The high-speed rail axle produced by the production method according to any one of claims 7 to 9, which comprises the following chemical components in percentage by mass: 0.26 to 0.29 percent of C, 0.25 to 0.35 percent of Si, 0.62 to 0.82 percent of Mn, 0.010 percent of trace of P, 0.010 percent of trace of S, 0.95 to 1.18 percent of Cr, 0.22 to 0.28 percent of Mo, 0.60 to 1.40 percent of Ni, 0.020 to 0.060 percent of V, 0.015 to 0.040 percent of Al, less than or equal to 0.20 percent of Cu, and the balance of Fe and other inevitable impurities.
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| CN202011023320.0A CN112080625A (en) | 2020-09-25 | 2020-09-25 | High-speed rail axle surface induction quenching process with speed per hour being more than or equal to 400 kilometers, high-speed rail axle and production method thereof |
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| CN202011023320.0A CN112080625A (en) | 2020-09-25 | 2020-09-25 | High-speed rail axle surface induction quenching process with speed per hour being more than or equal to 400 kilometers, high-speed rail axle and production method thereof |
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| CN114774644A (en) * | 2022-04-21 | 2022-07-22 | 武汉纺织大学 | ADI surface quenching process |
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